Overrunning alternator decoupling pulley design

ABSTRACT

A pulley assembly for an automobile auxiliary apparatus, such as an alternator, that dampens torsional impacts and reduces the stress on the auxiliary apparatus, the belt drive system and other apparatuses, by use of both a torsion spring and a one-way overrunning clutch mechanism allowing for the free run of the pulley shaft.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. application Ser.No. 14/207,316, filed Mar. 12, 2014 which is incorporated herein byreference in its entirety.

FIELD OF INVENTION

The invention relates generally to a pulley for an auxiliary apparatusof a vehicle engine which allows for the transfer of rotational energyto the auxiliary apparatus through a drive belt system while bothreducing harmful torsional impact events on the auxiliary apparatus, andallowing for the free overrun of the auxiliary apparatus when thevehicle engine makes sudden negative changes in speed.

BACKGROUND OF THE INVENTION

Most auxiliary apparatuses of a motor vehicle engine—such as thealternator, the power steering pump and the air conditioner compressorshaft—are driven by a serpentine belt connected to a pulley on thecrankshaft of an engine. The belt, in turn, drives pulleys on theauxiliary apparatuses.

It is well-known that the serpentine drive belt on a multi-cylinderengine seldom transmits constant torque to the various accessories whichit drives. As the pistons sequentially fire, there are sudden torsionalimpact forces transmitted through the belt to the auxiliary apparatuses.A driven apparatus, such as an alternator, may have significantrotational inertia resisting changes to its rotational velocity, whichcan cause stress on the serpentine belt and other apparatuses in thebelt system.

The prior art discloses the use of a one-way overrunning clutch for adriven pulley. The one-way clutch operates such that it only transmitstorque in one rotational direction. However, while such a design allowsan auxiliary apparatus to spin freely when the engine makes suddennegative changes in speed—such as when a down-shift occurs or when theengine is turned off—the use of a one-way clutch alone does not addressthe torsional impacts that occur due to the sequential firing of pistonsin a multi-cylinder engine, or other reasons.

The prior art further discloses the use of devices within a pulleyassembly to dampen or reduce the effect of harmful torsional impacts ina belt driven system. However, such prior art does not adequatelyaddress the situation described above, where a sudden reduction in thespeed of the engine occurs. In such a situation, while the dampingdevices may absorb some of the torsional impact, the significantrotational inertia of an auxiliary apparatus, such as an alternator,will cause a tremendous amount of stress on the belt and on other engineaccessories and apparatuses, potentially reducing the lives of suchparts.

Further, the manner in which the devices in the prior art attempt toreduce the effect of harmful torsional impacts is not as effective asthat disclosed in the present invention.

SUMMARY OF THE INVENTION

According to an embodiment of the invention, a pulley assembly comprisesan inner shaft with a damping element concentrically coupled to, anddisposed about, the inner shaft. An embodiment of the invention furthercomprises a one-way overrunning clutch disposed between the inner shaftand damping element, the one-way overrunning clutch being configured soas to permit torque to be transferred from the inner rotating element tothe inner shaft, and to substantially prevent the transfer of torquefrom the inner shaft to the inner rotating element. In a furtherembodiment of the invention, an outer pulley housing is disposed about,and spaced from, the damping element, such that minimal to no frictionexists between the damping element and the outer pulley housing, the topend of a helical torsion spring is matingly coupled to the dampingelement and the bottom end of the torsion spring is matingly coupled tothe outer pulley housing, whereby torsional impacts to the pulleyassembly are substantially reduced.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an exploded view of an overrunning alternator decouplingpulley in accordance with an embodiment of the invention.

FIG. 2 shows a sectional, isometric view of an overrunning alternatordecoupling pulley in accordance with an embodiment of the invention.

FIG. 3 shows a sectional, isometric view of an overrunning alternatordecoupling pulley in accordance with an embodiment of the invention.

FIG. 4 shows an exploded view of an overrunning alternator decouplingpulley in accordance with an embodiment of the invention.

FIG. 5 shows a sectional, isometric view of an overrunning alternatordecoupling pulley in accordance with an embodiment of the invention.

FIG. 5A shows an exploded view of a spring pocket formed by an innerspring retaining wall and an outer spring retaining wall in accordancewith an embodiment of the invention.

FIG. 6 shows an outer pulley housing member and a torsion spring inaccordance with an embodiment of the invention.

DETAILED DESCRIPTION

The invention relates generally to a decoupling pulley for an alternatorwhich allows for the transfer of rotational energy to the alternatorwhile isolating harmful torsional impact events inherent in belt systemsdriven by piston-driven engines. Torsional impacts occur in such beltsystems due, in part, to the sequential firing of pistons inpiston-driven engines. The invention utilizes a torsion spring whichflexes, or winds and un-winds, during such torsional impacts, therebyslowing the accelerative effect on the rotor of the alternator andreducing the stress on the serpentine belt and other components in thebelt system.

In addition, alternators have significant rotational inertia which maycause significant stress to the belt, and to other auxiliary apparatusesconnected to the belt system, when the engine driving the alternatorsuddenly slows down. Such stress may shorten the lives of both the beltand other auxiliary apparatuses. The invention incorporates dualball-bearings and a one-way overrunning clutch, e.g. a sprag clutch,which allows the alternator rotor to spin freely when the engine makessudden negative changes in speed, such as when a down-shift occurs orthe engine is turned off. The invention thereby reduces stress not onlyto the driven auxiliary apparatus, but to the drive belt and otherapparatuses connected to the belt drive system as well.

FIGS. 1 and 4 show a pulley assembly 1, including an inner shaft 30, aone-way overrunning clutch 20, a damping element 10, a torsion spring50, and an outer pulley housing 60. The one-way overrunning clutch 20,damping element 10, torsion spring 50, and outer pulley housing 60 areall concentrically configured and selectively rotatable around thelongitudinal axis of the inner shaft 30. The outer pulley housing 60 hasa substantially tubular shape with openings at a top end and a bottomend, as shown in FIGS. 1 and 5. It should be appreciated that the terms“top” and “bottom” are used for descriptive purposes only and not by wayof limitation. As shown in FIGS. 1-5, the outer pulley housing 60includes an outer periphery having groves 69 which are adapted to engagea serpentine drive belt (serpentine belt not shown). The serpentinedrive belt is typically driven by a driving apparatus (i.e. an engine)and drives an auxiliary apparatus (i.e. an alternator) via a pulleyapparatus, such as the pulley assembly 1 disclosed in the presentinvention.

As shown in FIGS. 1 and 5, in a preferred embodiment, the outer pulleyhousing 60 includes an inner curved surface having four separateportions: a first inner surface portion 63 towards the top of the outerpulley housing 60 having a first radius; a second inner surface portion61 having a second radius smaller than the first radius; a third innersurface portion 62 joining the first 63 and second 61 inner surfaceportions; and a fourth annular portion 68 at the bottom of the outerpulley housing 60 just below the second inner portion 61 and having athird radius smaller than the second radius. In a preferred embodiment,a first helical ramp member 64 begins on top of the fourth annularportion 68 and spirals upward along the second inner surface portion 61of the outer pulley housing 60. In an embodiment of the invention, thefirst helical ramp member 64 has an inner radius that is substantiallythe same as the third radius of the fourth annular portion 68 of theouter pulley housing 60. In a preferred embodiment, the top end 67 ofthe helical ramp member 64 is configured to matingly abut a bottom end52 of the torsion spring 50. Such a configuration allows torque that istransferred from the serpentine belt to the outer pulley housing 60 tobe transferred to the torsion spring 50 via the top end 67 of the firsthelical ramp member 64 which abuts the bottom end 52 of the torsionspring 50.

It should be appreciated that the portions of the outer pulley housing60 and the first helical ramp member 64 may be integral and machined outof a singular block of material. The invention encompasses to use of anyrib or protrusion from the inner surface of the outer pulley housing 60that is configured to abut, and transfer torque to, the bottom end 52 ofthe torsion spring 50. However, a ramp having the same or substantiallysimilar helical profile as the torsion spring 50 is preferred as itprovides the torsion spring 50 with additional support and stability.

In a preferred embodiment, the damping element 10 of the pulley assembly1 (see FIGS. 1, 4, and 6) includes three portions: a tubular top portion11 having an inner surface 12 of a fourth radius, a tubular bottomportion 14 having an inner surface of a fifth radius smaller than thefourth radius, and an annulus member 13 attaching the top portion 11 tothe bottom portion 14, the annulus member 13 having a top surface andbottom surface. In an embodiment of the invention, the annulus member 13has an inner radius substantially the same as the inner radius of thebottom portion 14. In a further embodiment of the invention, as shown inFIGS. 4 and 6, a second helical ramp member 18 spirals downward from thebottom surface of the annulus member 13, mirroring the upward spiralingfirst helical ramp member 64 described above. In a preferred embodiment,the damping element 10 sits within a cavity defined by inner curvedsurface of the outer pulley housing 60, specifically within a cavitydefined, in part, by the first inner surface portion 63 and the thirdinner surface portion 62. As described more fully below, in a preferredembodiment of the invention, the tubular top portion 11 of dampingelement 10 has an outer surface 15 which rotates relative to, but doesnot touch, the first inner surface portion 63 of the outer pulleyhousing 60 during operation of the invention.

In a preferred embodiment, the bottom end 17 of the second helical rampmember 18 is configured to matingly abut the top portion 54 of torsionspring 50. Such configuration allows torque to be transferred from thetorsion spring 50 to the damping element 10 via the top portion 54 ofthe torsion spring 50 which abuts the bottom end 17 of the secondhelical ramp member 18.

It should be appreciated that, similar to the outer pulley housing 60described above, the portions of the damping element 10 and the secondhelical ramp member 18 may be integral and machined out of a singularblock of material.

In a preferred embodiment, the torsion spring 50 is configured to flexduring torsional impacts transmitted to the pulley assembly 1 from adriving engine via a drive belt. Such torsional impacts result in thesudden acceleration or deceleration of the outer pulley housing 60 andmay be caused by the sequential firing of pistons in piston-drivenengines. The torsion spring 50 slows the accelerative effect of thetorsional impacts on an apparatus driven by the pulley assembly 1 andreduces the stress on the serpentine belt and other components in thebelt system. In various embodiments of the invention, the torsion spring50 may be of a circular cross-section (as shown in FIGS. 1 and 2), asquare-cross section (as shown in FIGS. 3-6) or any other shape.

It should be appreciated that, unlike pulley assembly configurationsdisclosed in the prior art, the torsion spring 50 of the presentinvention is not in frictional engagement with any portion of the pulleyassembly 1 and does not act as a clutch mechanism. That is, the torsionspring 50 in the present invention does not unwind or expand to a pointwhere it comes into contact with any portion of inner surface 61, 62, 63the outer pulley housing 60. In the prior art, springs used as clutchmechanisms are generally configured such that the spring unwinds as theinner shaft of the pulley assembly rotates faster than the outer pulleyhousing driven by the serpentine drive belt. In the present invention,the opposite occurs: the torsion spring 50 returns to its normal restingposition as the inner shaft 10 rotates faster than the outer pulleyhousing 60. As described more fully below, the torsion spring 50 ismeant to dampen the vibrations transferred to the pulley assembly 1 fromthe engine via the serpentine drive belt, not to act as a clutchmechanism.

In a preferred embodiment of the invention, the top portion 11 ofdamping element 10 contains a substantially cylindrical cavity having aperiphery defined in part by the inner surface 12 of the top portion 11of the damping element 10 and the top surface of the annulus member 13of the damping element 10. The cylindrical cavity contains, in apreferred embodiment, a one-way overrunning clutch 20 (e.g. a spragclutch) which sits within the top portion 11 of the damping element 10.In a preferred embodiment, the one-way overrunning clutch 20 isconcentrically configured and selectively rotatable around thelongitudinal axis of the inner shaft 30, the one-way overrunning clutch20 having an inner surface 24 configured to mate directly with, androtate in one direction with respect to, an outer surface 32 of theinner shaft 30. In addition, in an embodiment of the invention, theone-way overrunning clutch 20 has an outer surface that is press fitwith the inner surface of the top portion 11 of the damping element 10,such that an outer surface of the one-way overrunning clutch 20 and theinner surface 12 of the damping element 10 do not rotate in relation toone another. Such configuration allows the damping element 10 to drivethe inner shaft 30 when the damping element 10 rotates faster than theinner shaft 30, and allows the inner shaft 30 to disengage from, androtate freely with respect to, the damping element 10 when the dampingelement 10 rotates slower than the inner shaft 30.

FIGS. 1 and 2 further show two ball bearings 40, 80, which, inconjunction with the one-way overrunning clutch 20, allow for the innershaft 30 to rotate freely when the rotational velocity of the dampingelement 10 is less than the rotational velocity of the inner shaft 30.In a preferred embodiment, the one-way overrunning clutch 20 and ballbearings 40, 80 are concentrically configured around the longitudinalaxis of the inner shaft 30. A first ball bearing 40, having an outersurface 42 and inner surface 44, may be disposed at a top end of theouter pulley housing 60. The first ball bearing 40 may be configured soits outer surface 42 mates with an inner surface 72 of an end cap 70.The end cap 70 supports the first ball bearing 40 and offers protectionto the pulley assembly 1 from outside contaminants. The first ballbearing may also be configured so its inner surface 44 rotatably mateswith the inner shaft 30 or an axle of an auxiliary apparatus driven bythe pulley assembly 1.

A second ball bearing 80 may be disposed at the bottom end of the outerpulley housing 60 and configured so its outer surface 42 mates with aninner surface of the fourth annular portion 68 of the outer pulleyhousing 60. The second ball bearing 40 may also be configured so itsinner radial surface 44 rotatably mates with the inner shaft 30 or theaxle of an auxiliary apparatus being driven by the pulley assembly 1.The first and second ball bearings 40, 80 may be needle roller bearings,and may be press fit with the end cap 70 and outer pulley housing 60,respectively.

In an embodiment of the invention, the bottom of the pulley assembly 1further includes a spacer 90 which keeps the inner shaft 30 and theauxiliary apparatus driven by the pulley assembly 1 (e.g. an alternator)at an appropriate length for the pulley assembly 1 to functioneffectively.

In a preferred embodiment of the invention, when the components of thepulley assembly 1 are assembled together, the outer surface 15 ofdamping element 10 is spaced from the inner surface 63 of outer pulleyhousing 60 such that minimal to no friction exists between the outersurface 15 of damping element 10 and the inner surface 63 of outerpulley housing 60. In an embodiment of the invention, the dampingelement 10 only mates with outer pulley housing 60 via torsion spring50, which abuts the bottom end 17 of the second helical ramp member 18of the damping element 10 and the top end 67 of the first helical rampmember 64 of the inner surface of outer pulley housing 60. It should beappreciated that although the outer surface 15 of damping element 10 isspaced from the inner surface 63 of outer pulley housing 60 according toan embodiment of the invention, it is possible that a substance, such asa lubricant, on the inner surface 63 of outer pulley housing 60 or theouter surface 15 of damping element 10 may fill the space between thetwo surfaces. Even in such a case, however, very minimal friction willexist between the outer surface 15 of damping element 10 and the innersurface 63 of outer pulley housing 60.

According to an embodiment of the invention, the damping element 10 maybe lubricated on its outer surface Further, in preferred embodiment, theouter pulley housing only mates with the inner shaft 30 via (1) thesecond ball bearing 80, which allows the inner shaft 30 to rotateindependently from the outer pulley housing 60, and (2) the torsionspring 50, which, as just described, mates with damping element 10,which mates with one-way overrunning clutch 20, which mates with theinner shaft 30.

An illustrative example of the operation of an embodiment of theinvention follows. For the purposes of this example, initially allcomponents are in their resting positions, including torsion spring 50.As the outer pulley housing 60 receives torque from a car engine via theserpentine drive belt, it transfers the torque to the torsion spring 50via the first helical ramp member 64 of the outer pulley housing 60, theend 67 of which abuts the bottom end 52 of the torsion spring 50. Atthis time the torsion spring 50 unwinds a certain amount, the amount offlexure being dependent on the characteristics of the spring, afterwhich the torsion spring 50 transfers torque to the damping element 10.In a preferred embodiment, the torque is transferred from the torsionspring 50 to the damping element 10 via the top end 54 of the torsionspring 50, which abuts the second helical ramp member 18 attached todamping element 10. As explained above, in a preferred embodiment, thedamping element contains a one-way overrunning clutch 20, such as asprag clutch, which is preferably press fit into the top portion 11 ofthe damping element 10. The one-way overrunning clutch 10 transferstorque from the damping element 10 to the inner shaft 30, which isdirectly fixed to, and provides the torque necessary to rotate, therotor of the auxiliary apparatus (e.g. an alternator). In a preferredembodiment, the inner shaft 30 is supported within the pulley assembly 1by ball bearings 40, 80.

During the operation of a vehicle, sudden torsional impact forces, suchas those caused by firing of pistons in a multi-cylinder engine, may betransmitted from the serpentine drive belt to the outer pulley housing60 of the pulley assembly 1. The present invention utilizes the torsionspring 50 to absorb these harmful torsional impact forces by allowingthe damping element 10 to rotate, in a preferred embodiment, up toapproximately 60 degrees relative to the outer pulley housing 60. Asstated, it is the flexure of the torsion spring 50 that provides thepulley assembly 1 its vibration damping ability.

According to an embodiment of the invention, when such torsional impactforces cause the outer pulley housing 60 to rotate faster in the drivedirection than the inner shaft 30, the torsion spring 50 absorbs suchtorsion impact forces by unwinding or expanding. On the other hand, whensudden torsional impact forces cause the outer pulley housing 60 torotate slower than the inner shaft 30, the torsion spring 50 absorbssuch torsional impact forces by winding or compressing. If the torsionspring 50 were not present, such sudden torsional impact forces would bedirectly transmitted from the engine to the apparatus driven by thepulley assembly 1 causing vibration and stress to the apparatus, thedrive belt, and other apparatuses connected to the serpentine drive beltsystem.

According to an embodiment of the invention, as the outer pulley housing60 receives torque from a car engine via a serpentine drive belt, ittransfers the torque to the torsion spring 50 via the first helical rampmember of the outer pulley housing 60, the end 67 and 93 of which abutsthe bottom end 52 of the torsion spring 50 (see FIGS. 3 and 4). At thistime, the torsion spring 50 and transfers torque to the damping element10. The abutment of the damping element 10 may apply force to theopposite end 91 of the torsion spring 50 and cause it to expand. Inembodiments of the invention, if a high level of torque is applied, theopposite end 91 of the torsion spring 50 deforms far enough away fromthe coils of the spring to dislodge it from the damping element 10 andthen contact the outer pulley housing 60. This results in frictionbetween the torsion spring 50 and the outer pulley housing 60 andinterferes or reduces the damping capabilities of the invention. FIG. 5Aillustrates a spring pocket 90 formed by an inner spring retaining wall94 and an outer spring retaining wall 92 that is designed to keep thecoils of the torsion spring from becoming dislodged. By capturing thetop portion 91 (or opposite end) in the spring pocket 90, the torsionspring 50 is able to expand more uniformly and eliminate the possibilityof the torsion spring contacting the pulley housing. This embodiment isable to handle higher torque loads and more uniform vibration dampingthroughout the entire deflection range of the torsion spring.

In an embodiment of the invention, the size and pitch of the helicalramps, both in the pulley housing 60 and the damping element 10, are thesame size and pitch as the torsion spring 50. This is true whether thetorsion spring 50 has a circular cross-section (as illustrated in FIGS.1 and 2), a square cross-section (as illustrated in FIGS. 3 to 6), orany other shape. The uniformity of size, pitch and shape, creates arotational symmetry which helps avoid any dynamic imbalances. Thedynamic imbalances could cause undo vibration at high speeds if theramps have different sizes or pitches than the torsion spring.

Further, under conditions when the engine decelerates suddenly or isturned off, undue stress on the drive belt can be avoided if the rotorfor the auxiliary apparatus (e.g. alternator) driven by the pulleyassembly 1 is able to slow down at its own rate, or, stated differently,undue stress on the drive belt can be avoided if the inner shaft 30 ofthe pulley assembly 1 is able to free run when the rotational velocityof the outer pulley housing 60 is less than the rotational velocity ofthe inner shaft 30. Allowing for the free run of the inner shaft 30 isimportant because certain auxiliary apparatuses in an automobile, suchas an alternator, have significant rotational inertia which will resistchanges to their rotational velocity. Such resistance causes stress toand reduces the life of the drive belt and other apparatuses connectedto the belt drive system if the apparatus remains engaged to the beltdrive system when a sudden negative change in speed occurs by theapparatus driving the belt system, i.e. the engine. By allowing theinner shaft 30 of the pulley assembly 1 to spin freely, the stress tothe drive belt and other apparatuses is significantly reduced.

According to an embodiment of the present invention, the free run of theinner shaft 30 is accomplished as follows. As the rotational velocity ofthe outer pulley housing 60 decreases, the torsion spring 50 begins tounwind until it reaches its normally resting position. At this point, asthe rotational velocity of the outer pulley housing 60 continues todecrease, the one-way overrunning clutch 20 disengages from the innershaft 30 and allows the inner shaft 30 to freewheel. The inner shaft 30will continue to freewheel until it stops on its own, or until theengine accelerates to the point where the rotational velocity of theouter pulley housing 60 exceeds the rotational velocity of the innershaft 30.

What is claimed is:
 1. A pulley assembly comprising: (a) an inner shaft; (b) a damping element coupled to and disposed about the inner shaft; (c) a one-way overrunning clutch disposed between the inner shaft and the damping element, the one-way overrunning clutch selectively permitting torque to be transferred from the damping element to the inner shaft, and substantially preventing the transfer of torque from the inner shaft to the damping element; (d) an outer pulley housing disposed about and spaced from the damping element such that minimal to no friction exists between the damping element and the outer pulley housing; (e) a torsion spring, situated longitudinally along the axis of the inner shaft between the damping element and an inner portion of the outer pulley housing, the spring having a top end adjacent to the damping element and a bottom end adjacent to the interior section of the outer pulley housing, the top end of the torsion spring matingly coupled to the damping element and the bottom end of the torsion spring matingly coupled to the outer pulley housing, whereby torsional impacts to the pulley assembly are substantially reduced; (f) the damping element and the outer pulley housing include an integral spring pocket for matingly coupling to the torsion spring, the spring pocket having the same or similar helical profile as the torsion spring to prevent the spring from becoming dislodged from the damping element or outer pulley housing; and (g) the outer pulley housing includes a plurality of inner surface portions, the inner surface portions comprising a first inner surface portion towards a top of the outer pulley housing having a first radius, a second inner surface portion having a second radius smaller than the first radius, a third inner surface portion joining the first and second inner surface portions, and a fourth annual portion at a bottom of the outer pulley housing having a third radius smaller than the second radius
 2. The pulley assembly of claim 1, wherein: (a) the damping element includes a plurality of portions, the plurality of portions comprising a tubular top portion having an inner surface of a fourth radius, a tubular bottom portions having an inner surface of a fifth radius smaller than the fourth radius, and an annulus member attaching the tubular top portion to the tubular bottom portion; (b) the annulus member has a top surface and a bottom surface, and an inner radius substantially the same as the fifth radius; (c) a second helical ramp member begins on the bottom surface of the annulus member and spirals downward along the outer surface of the annulus member ending in a bottom end; (d) the bottom end of the second helical ramp member matingly abuts the top end of the torsion spring; (e) the outer pulley housing includes an inner surface, the inner surface comprising the first helical ramp member having a beginning and an end, the end of the first helical ramp member configured to abut the bottom end of the torsion spring; and (f) the damping element includes an outer surface, the outer surface comprising a second helical ramp member having a beginning and an end, the end of the second helical ramp member configured to abut the top end of the torsion spring.
 3. The pulley assembly of claim 1, wherein the torsion spring allows the damping element to rotate up to 60 degrees relative to the outer pulley housing.
 4. The pulley assembly of claim 1, wherein the torsion spring has a circular cross-section.
 5. The pulley assembly of claim 1, wherein the torsion spring has a square cross-section.
 6. The pulley assembly of claim 1, wherein the one-way overrunning clutch utilizes needle roller bearings.
 7. The pulley assembly of claim 1, further comprising a plurality of ball bearings allowing the inner shaft to rotate independently from the damping element when the rotational speed of the inner shaft is greater than the rotational speed of the damping element.
 8. The pulley assembly of claim 1, wherein the torsion spring unwinds as the rotational speed of the outer pulley housing is greater than, and increases relative to, the rotational speed of the damping element.
 9. A pulley assembly comprising: (a) an inner shaft; (b) a damping element coupled to and disposed about the inner shaft; (c) a one-way overrunning clutch disposed between the inner shaft and the damping element, the one-way overrunning clutch selectively permitting torque to be transferred from the damping element to the inner shaft, and substantially preventing the transfer of torque from the inner shaft to the damping element; (d) an outer pulley housing disposed about and spaced from the damping element such that minimal to no friction exists between the damping element and the outer pulley housing; (e) a torsion spring, situated longitudinally along the axis of the inner shaft between the damping element and an inner portion of the outer pulley housing, the spring having a top end adjacent to the damping element and a bottom end adjacent to the interior section of the outer pulley housing, the top end of the torsion spring matingly coupled to the damping element and the bottom end of the torsion spring matingly coupled to the outer pulley housing, whereby torsional impacts to the pulley assembly are substantially reduced; (f) the outer pulley housing includes a plurality of inner surface portions, the inner surface portions comprising a first inner surface portion towards a top of the outer pulley housing having a first radius, a second inner surface portion having a second radius smaller than the first radius, a third inner surface portion joining the first and second inner surface portions, and a fourth annual portion at a bottom of the outer pulley housing having a third radius smaller than the second radius; and (g) the inner diameter of the portion of the outer pulley housing disposed about the torsion spring is sized to limit the amount the torsion spring may expand such that damage to the torsion spring is avoided when the pulley assembly is subjected to torsional loads that cause the torsion spring to expand.
 10. The pulley assembly of claim 9, wherein: (a) the damping element includes a plurality of portions, the plurality of portions comprising a tubular top portion having an inner surface of a fourth radius, a tubular bottom portions having an inner surface of a fifth radius smaller than the fourth radius, and an annulus member attaching the tubular top portion to the tubular bottom portion; (b) the annulus member has a top surface and a bottom surface, and an inner radius substantially the same as the fifth radius; (c) a second helical ramp member begins on the bottom surface of the annulus member and spirals downward along the outer surface of the annulus member ending in a bottom end; (d) the bottom end of the second helical ramp member matingly abuts the top end of the torsion spring; (e) the outer pulley housing includes an inner surface, the inner surface comprising the first helical ramp member having a beginning and an end, the end of the first helical ramp member configured to abut the bottom end of the torsion spring; and (f) the damping element includes an outer surface, the outer surface comprising a second helical ramp member having a beginning and an end, the end of the second helical ramp member configured to abut the top end of the torsion spring.
 11. The pulley assembly of claim 9, wherein the torsion spring allows the damping element to rotate up to 60 degrees relative to the outer pulley housing.
 12. The pulley assembly of claim 9, wherein the torsion spring allows the damping element to rotate up to 60 degrees relative to the outer pulley housing.
 13. The pulley assembly of claim 9, wherein the torsion spring has a circular cross-section.
 14. The pulley assembly of claim 9, wherein the torsion spring has a square cross-section.
 15. The pulley assembly of claim 9, wherein the one-way overrunning clutch utilizes needle roller bearings.
 16. The pulley assembly of claim 9, further comprising a plurality of ball bearings allowing the inner shaft to rotate independently from the damping element when the rotational speed of the inner shaft is greater than the rotational speed of the damping element.
 17. The pulley assembly of claim 9, wherein the torsion spring unwinds as the rotational speed of the outer pulley housing is greater than, and increases relative to, the rotational speed of the damping element.
 18. A pulley assembly comprising: (a) an inner shaft; (b) a damping element coupled to and disposed about the inner shaft; (c) a one-way overrunning clutch disposed between the inner shaft and the damping element, the one-way overrunning clutch selectively permitting torque to be transferred from the damping element to the inner shaft, and substantially preventing the transfer of torque from the inner shaft to the damping element; (d) an outer pulley housing disposed about and spaced from the damping element such that minimal to no friction exists between the damping element and the outer pulley housing; (e) a torsion spring, situated longitudinally along the axis of the inner shaft between the damping element and an inner portion of the outer pulley housing, the spring having a top end adjacent to the damping element and a bottom end adjacent to the interior section of the outer pulley housing, the top end of the torsion spring matingly coupled to the damping element and the bottom end of the torsion spring matingly coupled to the outer pulley housing, whereby torsional impacts to the pulley assembly are substantially reduced; (f) the damping element and the outer pulley housing include an integral spring pocket for matingly coupling to the torsion spring, the spring pocket having the same or similar helical profile as the torsion spring to prevent the spring from becoming dislodged from the damping element or outer pulley housing; (g) the outer pulley housing includes a plurality of inner surface portions, the inner surface portions comprising a first inner surface portion towards a top of the outer pulley housing having a first radius, a second inner surface portion having a second radius smaller than the first radius, a third inner surface portion joining the first and second inner surface portions, and a fourth annual portion at a bottom of the outer pulley housing having a third radius smaller than the second radius; and (h) the inner diameter of the portion of the outer pulley housing disposed about the torsion spring is sized to limit the amount the torsion spring may expand such that damage to the torsion spring is avoided when the pulley assembly is subjected to torsional loads that may cause the torsion spring to expand.
 19. The pulley assembly of claim 18 wherein: (a) the damping element includes a plurality of portions, the plurality of portions comprising a tubular top portion having an inner surface of a fourth radius, a tubular bottom portions having an inner surface of a fifth radius smaller than the fourth radius, and an annulus member attaching the tubular top portion to the tubular bottom portion; (b) the annulus member has a top surface and a bottom surface, and an inner radius substantially the same as the fifth radius; (c) a second helical ramp member begins on the bottom surface of the annulus member and spirals downward along the outer surface of the annulus member ending in a bottom end; (d) the bottom end of the second helical ramp member matingly abuts the top end of the torsion spring; (e) the outer pulley housing includes an inner surface, the inner surface comprising the first helical ramp member having a beginning and an end, the end of the first helical ramp member configured to abut the bottom end of the torsion spring; and (f) the damping element includes an outer surface, the outer surface comprising a second helical ramp member having a beginning and an end, the end of the second helical ramp member configured to abut the top end of the torsion spring.
 20. The pulley assembly of claim 18, wherein the torsion spring allows the damping element to rotate up to 60 degrees relative to the outer pulley housing. 